U.S. patent application number 13/741731 was filed with the patent office on 2013-08-01 for methods for manipulating cutting elements for earth-boring drill bits and tools.
This patent application is currently assigned to Baker Hughes Incorporated. The applicant listed for this patent is David Keith Luce, Alan J. Massey, Crystal A. Parrot, Sean W. Wirth. Invention is credited to David Keith Luce, Alan J. Massey, Crystal A. Parrot, Sean W. Wirth.
Application Number | 20130197686 13/741731 |
Document ID | / |
Family ID | 42541071 |
Filed Date | 2013-08-01 |
United States Patent
Application |
20130197686 |
Kind Code |
A1 |
Luce; David Keith ; et
al. |
August 1, 2013 |
METHODS FOR MANIPULATING CUTTING ELEMENTS FOR EARTH-BORING DRILL
BITS AND TOOLS
Abstract
Methods include one or more of robotically positioning a cutting
element on an earth-boring tool, using a power-driven device to
move a cutting element on an earth-boring tool, and robotically
applying a bonding material for attaching a cutting element to an
earth-boring tool. Robotic systems are used to robotically position
a cutting element on an earth-boring tool. Systems for orienting a
cutting element relative to a tool body include a power-driven
device for moving a cutting element on or adjacent the tool body.
Systems for positioning and orienting a cutting element on an
earth-boring tool include such a power-driven device and a robot
for carrying a cutting element. Systems for attaching a cutting
element to an earth-boring tool include a robot carrying a torch
for heating at least one of a cutting element, a tool body, and a
bonding material.
Inventors: |
Luce; David Keith;
(Splendora, TX) ; Wirth; Sean W.; (Spring, TX)
; Massey; Alan J.; (Houston, TX) ; Parrot; Crystal
A.; (Helotes, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Luce; David Keith
Wirth; Sean W.
Massey; Alan J.
Parrot; Crystal A. |
Splendora
Spring
Houston
Helotes |
TX
TX
TX
TX |
US
US
US
US |
|
|
Assignee: |
Baker Hughes Incorporated
Houston
TX
|
Family ID: |
42541071 |
Appl. No.: |
13/741731 |
Filed: |
January 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12370516 |
Feb 12, 2009 |
8355815 |
|
|
13741731 |
|
|
|
|
Current U.S.
Class: |
700/117 ;
901/42 |
Current CPC
Class: |
Y10T 29/49993 20150115;
Y10T 29/49826 20150115; G05B 2219/45063 20130101; B25J 11/00
20130101; B25J 11/005 20130101; G05B 2219/39387 20130101; B23K
31/025 20130101; E21B 10/26 20130101; B25J 9/1697 20130101; Y10S
901/42 20130101; B21B 23/00 20130101; E21B 10/42 20130101; E21B
10/08 20130101; E21B 10/62 20130101; Y10T 156/10 20150115; E21B
10/00 20130101; G05B 2219/2616 20130101; B25J 9/1687 20130101; E21B
10/02 20130101; G05B 2219/40032 20130101; E21B 10/43 20130101; G05B
2219/39393 20130101 |
Class at
Publication: |
700/117 ;
901/42 |
International
Class: |
B23K 31/02 20060101
B23K031/02; B25J 11/00 20060101 B25J011/00 |
Claims
1. A method of attaching a cutting element to an earth-boring tool,
comprising: robotically positioning at least one cutting element at
least partially within a cutting element pocket defined by at least
one surface of a body of an earth-boring tool; and robotically
applying a bonding material to at least one of the at least one
cutting element and the at least one surface of the body of the
earth-boring tool defining the cutting element pocket.
2. The method of claim 1, further comprising using a power-driven
device to move the at least one cutting element within the cutting
element pocket
3. The method of claim 1, wherein robotically applying the bonding
material comprises: moving a torch and a device for dispensing
bonding material in three-dimensional space using at least one
robotic arm; dispensing bonding material from the device for
dispensing bonding material onto the at least one of the at least
one cutting element and the at least one surface of the body of the
earth-boring tool defining the cutting element pocket; and heating
the bonding material dispensed from the device for dispensing
bonding material using the torch.
4. The method of claim 3, further comprising: mounting the torch to
an end of the at least one robotic arm; and mounting the device for
dispensing bonding material to the end of the at least one robotic
arm.
5. A method of attaching a cutting element to an earth-boring tool,
comprising: positioning at least one cutting element at least
partially within a cutting element pocket defined by at least one
surface of a body of an earth-boring tool; and robotically applying
a bonding material to at least one of the at least one cutting
element and the at least one surface of the body of the
earth-boring tool defining the cutting element pocket.
6. A system for orienting a cutting element relative to an
earth-boring tool, comprising: a device configured to hold a body
of an earth-boring tool; and a power-driven device configured to
move a cutting element positioned within a cutting element pocket
defined by at least one surface of the body of an earth-boring tool
when a movable surface of the power-driven device is abutted
against the cutting element and the power-driven device is used to
move the movable surface relative to the cutting element.
7. The system of claim 6, further comprising a control system
configured under control of a computer program to control at least
one of the power-driven device and the device configured to hold a
body of an earth-boring tool.
8. The system of claim 7, wherein the device configured to hold a
body of an earth-boring tool comprises a robotic positioner.
9. The system of claim 7, wherein the control system is configured
under control of the computer program to control each of the
power-driven device and the device configured to hold a body of an
earth-boring tool.
10. The system of claim 6, wherein the power-driven device
comprises at least one of an electrical motor, a pneumatic motor,
and a hydraulic motor.
11. The system of claim 6, wherein the movable surface of the
power-driven device comprises a surface of at least one of a wheel
and a belt.
12. The system of claim 6, wherein the power-driven device is
carried by a robot.
13. The system of claim 12, wherein the robot comprises an
articulated robotic arm configured to move the power-driven device
in three-dimensional space about three or more axes of
movement.
14. A method of attaching a cutting element to an earth-boring
tool, comprising: at least substantially enclosing a body of an
earth-boring tool in a chamber; controlling an environment within
the chamber; and at least substantially automatically applying a
bonding material to at least one of a cutting element and a surface
of the body of the earth-boring tool defining at least one cutting
element pocket while the body of the earth-boring tool is in the
controlled environment within the chamber.
15. The method of claim 14, further comprising robotically
positioning at least one cutting element at least partially within
the cutting element pocket defined by the at least one surface of
the body of the earth-boring tool.
16. The method of claim 14, further comprising: abutting a movable
surface of a power-driven device against a surface of the at least
one cutting element; and moving the movable surface of the
power-driven device to cause the at least one cutting element to
move within the cutting element pocket.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application
Ser. No. 12/370,516, filed Feb. 12, 2009, which will issue as U.S.
Pat. No. 8,355,815 on Jan. 15, 2013, the disclosure of which is
hereby incorporated herein by this reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to methods, systems, and
devices for at least partially automated manipulation of cutting
elements with respect to earth-boring rotary drill bits and other
earth-boring tools with which such cutting elements may be
associated. More particularly, the present invention relates to
methods, systems, and devices for at least partially automated
positioning of cutting elements on earth-boring tools, bonding of
cutting elements to earth-boring tools, and/or removal of cutting
elements from earth-boring tools.
BACKGROUND
[0003] Earth-boring tools are used to form wellbores in
subterranean formations and include, for example, rotary drill bits
(e.g., rolling cutter drill bits, fixed-cutter drag bits, bi-center
bits, eccentric bits, and coring bits), percussion drill bits,
reamers (including underreamers), and mills.
[0004] An earth-boring rotary drill bit 100 is shown in FIG. 1 that
includes a bit body 102. The bit body 102 may be predominantly
comprised of a particle-matrix composite material or a metal alloy
such as steel. As shown in FIG. 1, the bit body 102 may be secured
to a shank 104 having a threaded connection portion 106 (which may
conform to industry standards such as those promulgated by the
American Petroleum Institute (API)) for attaching the drill bit 100
to a drill string (not shown). The bit body 102 may be secured to
the shank 104 using a blank or an extension 108, which also may be
predominantly comprised of a metal alloy such as steel, although
the bit body 102 optionally may be secured directly to the shank
104.
[0005] The bit body 102 shown in FIG. 1 includes internal fluid
passageways (not shown) that extend between the face 103 of the bit
body 102 and a longitudinal bore or plenum (not shown), which
extends through the shank 104, the extension 108, and partially
through the bit body 102. Nozzle inserts 124 are provided at the
face 103 of the bit body 102 within the internal fluid passageways.
The bit body 102 includes a plurality of blades 116 that are
separated by junk slots 118. Gage pads 122 and wear knots 128 are
also provided on the bit body 102. A plurality of cutting elements
110 (which may include, for example, PDC cutting elements) are
attached to the face of the bit body 102 in cutting element pockets
112 that are located along each of the blades 116. The cutting
elements 110 may be generally cylindrical, and may have a front
cutting face 114 and a generally cylindrical lateral side surface
115.
[0006] When fabricating an earth-boring tool, such as the rotary
drill bit 100 shown in FIG. 1, for example, the cutting elements
110 are secured to the body of the earth-boring tool by manually
brazing each cutting element 110 into a cutting element pocket 112
previously formed in the body of the earth-boring tool. For
example, a cutting element 110 is manually inserted into a cutting
element pocket 112, after which a torch (not shown) may be used to
heat the cutting element 110 and the body of the tool adjacent the
cutting element pocket 112. After heating the cutting element 110
and the body to an elevated temperature (e.g., about 500.degree.
C.-700.degree. C.), the torch may be used to manually heat and melt
a metal or metal alloy brazing material, and the molten brazing
material may be manually applied to the interface between the
cutting element 110 and the surfaces of the body defining the
cutting element pocket 112 therein. As the molten brazing material
is applied to the interface between the cutting element 110 and the
surfaces of the body defining the cutting element pocket 112, the
cutting element 110 may be rotated or spun within the cutting
element pocket 112 in an effort to at least substantially fill the
gap or gaps between the cutting element 110 and the surfaces of the
body defining the cutting element pocket 112 at the interface
therebetween.
[0007] Such manual processes are often conducted by two persons,
one of which operates the torch and applies the molten brazing
material to the interface between the cutting element 110 and the
surfaces of the body defining the cutting element pocket 112, and
the other of which rotates the cutting element 110 within the
cutting element pocket 112 as the molten brazing material is
applied to the interface between the cutting element 110 and the
surfaces of the body defining the cutting element pocket 112.
BRIEF SUMMARY
[0008] In some embodiments, the present invention includes methods
of robotically positioning at least one cutting element on an
earth-boring tool. The at least one cutting element may be carried
by a robot configured to move the at least one cutting element in
three-dimensional space. For example, the at least one cutting
element may be loaded in a fixture carried by the robot, and
computer code may be executed in an electronic control system that
at least partially controls the robot. Execution of the computer
code may cause the robot to at least substantially automatically
position the at least one cutting element on or adjacent an
earth-boring tool. For example, the robot may be caused to position
the at least one cutting element at least partially within a
cutting element pocket defined by at least one surface of a body of
an earth-boring tool.
[0009] Additional embodiments of the present invention include
methods of attaching at least one cutting element to an
earth-boring tool in which a cutting element is positioned at least
partially within a cutting element pocket defined by at least one
surface of a body of an earth-boring tool, a power-driven device is
used to move the cutting element within the cutting element pocket,
and a bonding material is applied to an interface between the
cutting element and the body of the earth-boring tool. For example,
a cutting element may be manually or robotically positioned at
least partially within a cutting element pocket defined by at least
one surface of a body of an earth-boring tool. A movable surface of
a power-driven device may be abutted against a surface of the
cutting element, and the movable surface of the power-driven device
may be moved to cause the cutting element to rotate within the
cutting element pocket. Bonding material may be manually or
robotically applied to an interface between the cutting element and
a surface of the body before rotating the cutting element using the
power-driven device, while rotating the cutting element using the
power-driven device, and/or after rotating the cutting element
using the power-driven device.
[0010] Additional embodiments of the present invention include
methods of robotically positioning at least one cutting element on
an earth-boring tool in which a cutting element is robotically
positioned in a pocket defined by at least one surface of a body of
an earth-boring tool, and a power-driven device is used to rotate
the cutting element within the cutting element pocket.
[0011] Additional embodiments of the present invention include
methods of attaching at least one cutting element to an
earth-boring tool in which a cutting element is manually or
robotically positioned in a pocket defined by at least one surface
of a body of an earth-boring tool, and a bonding material is
robotically applied to an interface between the cutting element and
the at least one surface of the body of the earth-boring tool
defining the cutting element pocket.
[0012] In yet further embodiments, the present invention includes
systems for orienting a cutting element relative to an earth-boring
tool. The systems include a device configured to hold a body of an
earth-boring tool and a power-driven device configured to rotate a
cutting element positioned within a cutting element pocket defined
by at least one surface of the body of the earth-boring tool when a
movable surface of the power-driven device is abutted against the
cutting element and the power-driven device is used to move the
movable surface relative to the cutting element.
[0013] Additional embodiments of the present invention include
systems for positioning and orienting at least one cutting element
on a body of an earth-boring tool. The systems include a device
configured to hold a body of an earth-boring tool, a robot carrying
a fixture configured to hold at least one cutting element to be
attached to a body of an earth-boring tool, and a power driven
device configured to rotate a cutting element positioned within a
cutting element pocket defined by at least one surface of a body of
an earth-boring tool when a movable surface of the power-driven
device is abutted against the cutting element and the power-driven
device is used to move the movable surface relative to the cutting
element.
[0014] Yet further embodiments of the present invention include
systems for attaching at least one cutting element to an
earth-boring tool that include a device configured to hold a body
of an earth-boring tool, a robot carrying a fixture configured to
hold at least one cutting element to be attached to a body of an
earth-boring tool, and an additional robot carrying a torch for
heating at least one of a cutting element, a body of an
earth-boring tool, and a bonding material for bonding a cutting
element to a body of an earth-boring tool.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] While the specification concludes with claims particularly
pointing out and distinctly claiming that which is regarded as the
present invention, the advantages of this invention may be more
readily ascertained from the description of embodiments of the
invention when read in conjunction with the accompanying drawings,
in which:
[0016] FIG. 1 is a perspective view of an earth-boring tool having
a body and cutting elements that may be manipulated using
embodiments of methods, systems, and devices of the present
invention;
[0017] FIG. 2 is a schematic representation of an embodiment of a
system of the present invention that may be used to manipulate
cutting elements for earth-boring tools;
[0018] FIG. 3A is a perspective view of an embodiment of a system
of the present invention that may be used to manipulate cutting
elements and bodies of earth-boring tools;
[0019] FIG. 3B is a side view of the system shown in FIG. 3A;
[0020] FIG. 4A is a perspective view like that of FIG. 3A
illustrating components of the system shown in FIG. 3A in different
positions;
[0021] FIG. 4B is a side view of the system shown in FIG. 4A;
[0022] FIG. 5 is a perspective view of an embodiment of a cutter
holding device of the present invention that may be used in
conjunction with embodiments of systems of the present invention,
such as those represented in FIGS. 2, 3A, 3B, 4A, and 4B;
[0023] FIG. 6 is a perspective view illustrating the cutter holding
device shown in FIG. 5 being used to position a cutting element in
a cutting element pocket in a body of an earth-boring tool;
[0024] FIG. 7 is a perspective view of an embodiment of a
power-driven device of the present invention that may be used in
conjunction with embodiments of systems of the present invention,
such as those represented in FIGS. 2, 3A, 3B, 4A, and 4B, to drive
movement (e.g., rotation) of a cutting element disposed on or
adjacent a body of an earth-boring tool;
[0025] FIG. 8 is a perspective view illustrating the power-driven
device shown in FIG. 7 being used to drive rotation of a cutting
element in a cutting element pocket of a body of an earth-boring
tool;
[0026] FIG. 9 is a partial perspective view illustrating the cutter
holding device shown in FIG. 5 being used to position a cutting
element in a cutting element pocket of a body of an earth-boring
tool, and a portion of a cutting bonding system in position for
bonding the cutting element to the body of the earth-boring tool;
and
[0027] FIGS. 10A and 10B are flowcharts used for illustrating
methods that may be used to generate a computer program for
controlling systems like those shown in FIGS. 2, 3A, 3B, 4A and
4B.
DETAILED DESCRIPTION
[0028] Illustrations presented herein are not meant to be actual
views of any particular device or system, but are merely idealized
representations which are employed to describe the present
invention. Additionally, elements common between figures may retain
the same numerical designation.
[0029] An embodiment of a cutting element attachment system 200 of
the present invention is represented schematically in FIG. 2. The
cutting element attachment system 200 shown in FIG. 2 includes a
robotic tool body handling system 210, a robotic cutter handling
system 220, and a robotic cutter bonding system 230. The cutting
element attachment system 200 also includes a main control system
250, which may be used to control and/or electrically communicate
with one or more of the controllable subsystems and devices of the
cutting element attachment system 200. Each of these systems and
devices is described in further detail below.
[0030] The robotic tool body handling system 210 is a system for
holding and manipulating a body 102 of an earth-boring tool such
as, for example, the bit body 102 of the drill bit 100 shown in
FIG. 1, as cutting elements 110 are attached thereto. The tool body
handling system 210 may comprise a workpiece positioner 212
comprising a robotic device having a chuck or other device that may
be used to secure the body 102 of an earth-boring tool to the
robotic device. The positioner 212 may be configured to move the
body 102 of an earth-boring tool in three-dimensional space about
two (2) or more axes of movement. In other words, the positioner
212 may have at least two degrees of freedom in movement. By way of
example and not limitation, the positioner 212 may comprise a
so-called "tilt/rotate" positioner, or the positioner 212 may
comprise a "dual-axis orbital" (also referred to as a "skyhook")
positioner. Such workpiece positioners are commercially available
from, for example, ABB Ltd. of Zurich Switzerland, which has
corporate headquarters for North America in Norwalk, Conn.
[0031] The robotic tool body handling system 210 also may comprise
a controller 214 for controlling the active elements of the robotic
device of the positioner 212 and for electrically communicating
with (e.g., receiving electronic signals from and/or sending
electronic signals to) the main control system 250 of the of the
cutting element attachment system 200.
[0032] With continued reference to FIG. 2, the robotic cutter
handling system 220 includes a robot 222 for positioning a cutting
element 110 on or adjacent a surface of a body 102 of an
earth-boring tool held by the positioner 212, as well as a
controller 221 for controlling the robot 222 and electrically
communicating with the main control system 250 of the cutting
element attachment system 200. The robot 222 may comprise, for
example, an articulated robotic arm capable of moving a cutting
element 110 in three-dimensional space about three (3) or more
axes. In other words, the robot 222 may have three or more (e.g.,
three, four, five, six, etc.) degrees of freedom in movement of a
cutting element 110 carried by the robot 222. Articulated robotic
arms that may be used as a robot 222 of the present invention are
also commercially available from, for example, ABB Ltd. of Zurich
Switzerland, which has corporate headquarters for North America in
Norwalk, Conn.
[0033] The robotic cutter handling system 220 further includes a
cutter holding device 224 for holding a cutting element 110 as the
cutting element 110 is positioned on or adjacent a surface of a
body 102 of an earth-boring tool using the robot 222. In some
embodiments, the cutter holding device 224 may comprise, for
example, a three point chuck. In other embodiments, the cutter
holding device 224 may comprise a two point pinching device, a
magnetic gripper, a vacuum gripper (a vacuum chuck), a concentric
sleeve, an adhesive member (e.g., dual sided tape) or any other
device that is capable of selectively gripping and releasing
cutting elements 110 to be positioned on or adjacent the body 102
of an earth-boring tool held by the positioner 212. Furthermore, in
some embodiments, the cutter holding device 224 may be configured
to grip a cutting element 110 by a lateral side surface 115 of the
cutting element 110. In other embodiments, the cutter holding
device 224 may be configured to hold a cutting element 110 by a
front cutting face 114 of a cutting element 110. The cutter holding
device 224 may be in electrical communication with the controller
221 and/or the main control system 250, and the controller 221
and/or the main control system 250 may be used to cause the cutter
holding device 224 to selectively hold and release a cutting
element 110 as the cutting element 110 is manipulated using the
cutting element attachment system 200. In yet further embodiments,
a graspable feature may be provided on a cutting element 110 such
as, for example, a recess (e.g., a hole or a slot) in a surface of
the cutting element 110 or a protrusion (e.g., a post) that
protrudes outwardly from a surface of the cutting element 110, and
the cutter holding device 224 may include a device configured to
grasp the graspable feature provided on the cutting element
110.
[0034] Cutting elements 110 to be attached to a body 102 of an
earth-boring tool may be pre-loaded into a tray that is positioned
at a known, fixed location relative to the robot 222, and the robot
222 and cutter holding device 224 may be used to sequentially pick
cutting elements 110 from the tray and to place them into position
on the body 102 of the earth-boring tool. In other embodiments, the
cutter holding device 224 may include a cartridge that is preloaded
with a plurality of cutting elements 110 to be attached to the body
102 of the earth-boring tool.
[0035] The robotic cutter handling system 220 may also comprise a
power-driven device 226 for rotating or otherwise manipulating a
cutting element 110 after the cutting element 110 has been
positioned within a cutting element pocket 112 of a body 102 of an
earth-boring tool using the robot 222 and the cutter holding device
224. As used herein, the term "power-driven device" means and
includes any device having a movable component or portion, movement
of which is driven by power supplied from a non-human power source
(e.g., an electrical power source, a hydraulic power source, a
pneumatic power source, etc.). As discussed in further detail
below, it may be necessary or desirable to rotate or otherwise
manipulate a cutting element 110 within a cutting element pocket
112 as bonding material is applied to an interface between the
cutting element 110 and a surface of the body 102 defining the
cutting element pocket 112. Furthermore, it may be necessary or
desirable to rotate or otherwise manipulate a cutting element 110
within a cutting element pocket 112 into a selected, predetermined
orientation relative to the body 102 as the cutting element 110 is
attached to the body 102.
[0036] The power-driven device 226 may be carried by the robot 222
in a manner similar to that of the cutter holding device 224, thus
allowing the robot 222 to move the power-driven device 226 in
three-dimensional space about three (3) or more axes of movement.
Thus, after the robot 222 positions a cutting element 110 held by
the cutter holding device 224 into a cutting element pocket 112,
the cutter holding device 224 may be caused to release the cutting
element 110, and the robot 222 may be used to move the power-driven
device 226 into position relative to the cutting element 110 to
allow the power-driven device 226 to rotate or otherwise manipulate
the cutting element 110 within the cutting element pocket 112.
[0037] The power-driven device 226 may include, for example, a belt
or wheel having a surface that, when abutted against a generally
cylindrical lateral side surface 115 of a cutting element 110 and
caused to move in relation thereto, causes the cutting element 110
to rotate through an arc of greater than 360.degree. about a
longitudinal axis of the cutting element 110 within the cutting
element pocket 112. Thus, the power-driven device 226 may be said
to be configured to "spin" a cutting element 110 within a cutter
element pocket 112. As used herein the term "rotate" includes and
encompasses spinning.
[0038] The cutter holding device 224 and the power-driven device
226 are represented in FIG. 2 as being two physically separate
devices that are each carried by the robot 222. In additional
embodiments, the cutter holding device 224 and the power-driven
device 226 may be part of a single device. For example, a magnetic
or vacuum chuck that is capable of holding a cutting element 110 by
a front cutting face 114 of the cutting element 110 may be
configured to be rotatable along a rotational axis that is at least
substantially aligned with a central longitudinal axis of a cutting
element 110 when the cutting element 110 is held by the magnetic or
vacuum chuck. In such embodiments, the magnetic or vacuum chuck may
be used to hold a cutting element 110 as the robot 222 positions
the cutting element 110 into cutting element pocket 112. After
positioning the cutting element 110 at least partially within the
cutting element pocket 112, and prior to releasing the cutting
element 110 from the magnetic or vacuum chuck, the magnetic or
vacuum chuck may be caused to rotate about its axis of rotation,
thereby causing the cutting element 110 held by the magnetic or
vacuum chuck to rotate about the central longitudinal axis of a
cutting element 110 within the cutting element pocket 112.
[0039] The robotic cutter handling system 220 may comprise a power
source 227 for supplying power to the power-driven device 226. The
power source 227 may comprise, for example, an electrical motor, a
pneumatic motor, or a hydraulic motor.
[0040] The robotic cutter handling system 220 may further comprise
one or more sensors 228. The one or more sensors 228 may be used to
determine, for example, a position of a cutting element 110 in
three-dimensional space, a position of a surface of a body 102 of
an earth-boring tool in three-dimensional space, and/or a
rotational orientation of a cutting element 110 within a cutting
element pocket 112. For example, in some applications, it may be
necessary or desirable to provide a particular rotational
orientation of a cutting element 110 within a cutting element
pocket 112. A mark or feature may be provided on an exterior
surface of the cutting element 110, and the sensor 228 may be used
to sense a position of the mark or feature on the cutting element
110. In such embodiments, the power-driven device 226 may be used
to rotate a cutting element 110 within a cutting element pocket 112
until the sensor 228 senses that the mark or feature on the cutting
element 110 is in a desirable position, at which time the
controller 221 may be used to control the power-driven device 226
to cease rotation of the cutting element 110 such that the cutting
element 110 is provided in the desirable rotational orientation
with the cutting element pocket 112. By way of example and not
limitation, the sensor 228 may comprise a camera, a laser distance
finder, a proximity sensor, or a point contact sensor.
[0041] In the configuration described above, five (5) or more
degrees of freedom in movement may be provided between the body 102
of an earth-boring tool held by the positioner 212 and a cutting
element 110 carried by the cutter holding device 224 and the robot
222.
[0042] With continued reference to FIG. 2, the robotic cutter
bonding system 230 includes a robot 232 carrying one or more
devices that may be used to bond a cutting element 110 to a body of
an earth-boring tool after the robotic cutter handling system 220
has been used to position the cutting element 110 adjacent the body
102. The robotic cutter bonding system 230 also includes a
controller 231 for controlling the robot 232 and communicating
electrically with the main control system 250 of the cutting
element attachment system 200. The robot 232 also may comprise, for
example, an articulated robotic arm capable of moving one or more
devices carried thereby in three-dimensional space about three (3)
or more axes. In other words, the robot 232 may have three or more
(e.g., three, four, five, six, etc.) degrees of freedom in movement
of the one or more devices carried by the robot 232. Articulated
robotic arms that may be used as a robot 232 of the present
invention are commercially available from, for example, ABB Ltd. of
Zurich Switzerland, which has corporate headquarters for North
America in Norwalk, Conn. In some embodiments, the robot 232 of the
robotic cutter bonding system 230 may be substantially similar to
the robot 222 of the robotic cutter handling system 220.
[0043] The robotic cutter bonding system 230 may comprise a
dispensing device 234 carried by the robot 232. The dispensing
device 234 may be configured for dispensing bonding material for
use in bonding a cutting element 110 to a body 102 of an
earth-boring tool. For example, a metal alloy bonding material
(e.g., a brazing material) may be used to bond a cutting element
110 to a body 102. Such a metal alloy bonding material may be
supplied in wire form, and the dispensing device 234 may comprise a
wire feeder device. Such wire feeder devices are known in the art
and commercially available from, for example, Miller Electric Mfg.
Co. of Appleton, Wis. In additional embodiments, a metal alloy
bonding material (e.g., a brazing material) may be supplied in a
paste form, and the dispensing device 234 may comprise a nozzle or
aperture for dispensing paste therefrom.
[0044] Bonding material may be supplied to the dispensing device
234 from a source 235 of bonding material. The source 235 of
bonding material may comprise, for example, a spool of a wire of
bonding material. In additional embodiments, other bonding
materials may be used. For example, an epoxy-based material may be
used to bond a cutting element 110 to a body 102 of an earth-boring
tool. In such embodiments, the dispensing device 234 may comprise a
nozzle configured to direct liquid epoxy-based material therefrom,
the source 235 of bonding material may comprise a container of
liquid epoxy-based material, and a conduit (e.g., a hose or tube)
may be used to supply liquid epoxy-based material from the
container to the nozzle. Furthermore, the bonding material may
comprise a brazing material in paste form.
[0045] In yet further embodiments, a bonding material may be
pre-applied to surfaces of one or both of a cutting element 110 and
the body 102 of an earth-boring tool such that the robotic cutter
bonding system 230 need not include a dispensing device 234 for
dispensing the bonding material. In yet further embodiments, a foil
comprising a metal brazing alloy may be provided between a cutting
element 110 and the body 102 of an earth-boring tool, and the foil
may be heated to melt the foil and braze the cutting element 110 to
the body 102.
[0046] The robotic cutter bonding system 230 may further comprise a
torch 236 or other heat source for heating at least one of a
cutting element 110, a body 102 of an earth-boring tool, and a
bonding material dispensed by the dispensing device 234. For
example, in embodiments in which a metal alloy bonding material is
used, the torch 236 may comprise, for example, an acetylene torch,
an oxy-acetylene torch, or an arc-welding torch (a tungsten-inert
gas (TIG) arc welding torch or a plasma transferred arc (PTA)
welding torch), which may be used to melt the metal alloy bonding
material to facilitate application of molten metal alloy bonding
material to an interface between a surface of a cutting element 110
and an adjacent surface of a body 102 of an earth-boring tool. If
the torch 236 employs combustion of a fuel, the robotic cutter
bonding system 230 may comprise a source 237 of fuel (e.g.,
acetylene, a mixture of oxygen and acetylene, or another
combustible fuel gas mixture) for supplying fuel to the torch
236.
[0047] In additional embodiments, the robotic cutter bonding system
230 may comprise an induction heater or one or more lasers in place
of, or in addition to, the torch 236 for heating at least one of a
cutting element 110, a body 102 of an earth-boring tool, and a
bonding material dispensed by the dispensing device 234.
[0048] The dispensing device 234 for dispensing bonding material
and the torch 236 each may be in electrical communication with, and
selectively controllable by, the controller 231. Furthermore, the
controller 231 may be in electrical communication with the main
control system 250, as are the controller 214 of the tool body
handling system 210 and the controller 221 of the cutter handling
system 220, to allow the main control system 250 to coordinate and
control the movement of the various systems and devices of the
cutting element attachment system 200.
[0049] In yet further embodiments, the robotic cutter bonding
system 230 may comprise a device for friction welding a cutting
element 110 to a body 102. For example, at least a portion of an
outer surface of a cutting element 110 may be coated with a metal
alloy (or at least a portion of the body 102 within a cutting
element pocket 112, or both, may be coated with the metal alloy),
and the robotic cutter bonding system 230 may be configured to
rotate the cutting element 110 within the cutting element pocket
112 in such a matter as to generate friction between the body 102
and the metal alloy coating on the cutting element 110 to result in
a friction weld between the body 102 and the cutting element
110.
[0050] The robotic cutter bonding system 230 may further comprise
one or more sensors 238. The one or more sensors 238 may be used to
determine, for example, a position of at least one of the device
for dispensing bonding material 234, the torch 236, a surface of a
body 102 of an earth-boring tool, and a surface of a cutting
element 110 in three-dimensional space. By way of example and not
limitation, the one or more sensors 238 may comprise a camera, a
laser distance finder, a proximity sensor, or a point contact
sensor.
[0051] In additional embodiments, the device for dispensing bonding
material 234 and the torch 236 may be carried by separate, but
similar, articulated robotic arms, which may improve the ability of
the components of the robotic cutter bonding system 230 to access
all required locations on the complex geometry of a body 102 of an
earth-boring tool.
[0052] As shown in FIG. 2, the cutting element attachment system
200 may include one or more additional sensors 240, which may be in
direct or indirect electrical communication with the main system
controller 250. By way of example and not limitation, the sensor or
sensors 240 may comprise a vision system configured to acquire one
or more images of a body 102 of an earth-boring tool, and to
electrically and at least substantially automatically analyze such
images using one or more algorithms. For example, the images
acquired by such a vision system may be used to identify a position
and/or orientation of the body 102 in three-dimensional space, or
to identify a shape and/or size of a cutting element pocket 112 in
which a cutting element 110 is to be attached using the cutting
element attachment system 200. Such vision systems and software
that may be used to electrically and at least substantially
automatically analyze images acquired thereby are commercially
available from, for example, Cognex Corporation of Natick,
Mass.
[0053] Techniques for analyzing images acquired by vision systems
to determine shape, position, and/or orientation of objects
represented in such images are known in the art and disclosed in,
for example, U.S. Pat. No. 5,923,781 to Csipkes et al., which is
entitled "Segment Detection System and Method," U.S. Pat. No.
6,665,066 to Nair et al., which is entitled "Machine Vision System
and Method for Analyzing Illumination Lines in an Image to
Determine Characteristics of an Object Being Inspected," and U.S.
Pat. No. 7,305,115 to King, which is entitled "Method and System
for Improving Ability of a Machine Vision System to Discriminate
Features of a Target," U.S. Patent Application Publication No.
2005/0013465 A1 to Southall et al., which is entitled "Method and
Apparatus for Refining Target Position and Size Estimates Using
Image and Depth Data," and U.S. Patent Application Publication No.
2008/0069445 A1 to Weber, which is entitled "Image Processing
Apparatus and Methods," the disclosures of which are incorporated
herein in their entirety by this reference. Such methods, or
methods substantially similar to such methods, may be used to
identify an actual position and/or orientation of the body 102 in
three-dimensional space, or to identify an actual size, position,
and/or orientation of a cutting element pocket 112 in which a
cutting element 110 is to be attached.
[0054] By way of example and not limitation, a camera of a vision
system may be placed in front of a cutting element pocket 112 and
aligned with a longitudinal axis of the cutting element pocket 112
to acquire an image of the generally circular surface of the body
102 at the back of the cutting element pocket 112. If axial
alignment of the camera with the longitudinal axis of the cutting
element pocket 112 is not achieved to within approximately
one-eighth of an inch, a portion of the surface of the body 102 at
the back of the cutting element pocket 112 may be occluded in the
acquired image. After aligning the camera of the vision system with
the longitudinal axis of the cutting element pocket 112, an image
of the surface of the body 102 at the back of the cutting element
pocket 112 may be acquired using the camera of the vision system.
After acquiring the image, the image may be analyzed to identify
the location of at least a portion of the circumferential boundary
of the circular surface of the body 102 at the back of the cutting
element pocket 112. The center of the cutting element pocket 112
then may be determined from the location and radius of the portion
of the circumferential boundary of the circular surface of the body
102 at the back of the cutting element pocket 112. In some
situations, other portions of the body 102 of the earth-boring tool
may physically obstruct the field of view of the camera such that
the camera cannot acquire a full image of the entire circular
surface of the body 102 at the back of the cutting element pocket
112. In such situations, the region of interest in the acquired
image may be selected to include only a visible portion of the
circumferential boundary of the circular surface of the body 102 at
the back of the cutting element pocket 112, and only the visible
portion of the circumferential boundary of the circular surface of
the body 102 may be used to determine the center of the cutting
element pocket 112. Lights may be used to enhance the contrast in
the images acquired by the camera of the vision system and improve
the accuracy with which the location of the cutting element pocket
112 is determined.
[0055] In additional embodiments, the one or more sensors 240 may
include one or more of a temperature sensor for determining a
temperature of at least a portion of a body 102 of an earth-boring
tool or a cutting element 110, a tactile sensor for determining a
location of a surface of a body 102 or a cutting element 110 in
three-dimensional space, and a laser sensor for determining a
location of a surface of a body 102 or a cutting element 110 in
three-dimensional space. X-ray sensors and/or ultrasonic sensors
also may be used to identify locations and orientations of one or
more features of a body 102 of an earth-boring tool.
[0056] The main control system 250 of the cutting element
attachment system 200 may include an electronic signal processor
252, as well as memory 254 for storing data in electrical
communication with the electronic signal processor 252. The main
control system 250 may further include at least one input device
256 such as, for example, a keyboard or a mouse, for inputting data
or information into the main control system 250, and at least one
output device 258 such as, for example, a printer, a monitor, or a
screen, for outputting data or information from the main control
system 250.
[0057] In the configurations described hereinabove, the cutting
element attachment system 200 may be used to at least substantially
automatically (e.g., robotically) attach one or more cutting
elements 110 to a body 102 of an earth-boring tool. The positioner
212 may be used to manipulate a body 102 of an earth-boring tool,
and the robot 222 may be used to manipulate a cutting element 110
carried by the cutter holding device 224 so as to at least
substantially automatically position the cutting element 110 within
a cutting element pocket 112 of the body 102. After positioning the
cutting element 110 within a cutting element pocket 112 of the body
102, the power-driven device 226 may be used to rotate the cutting
element 110, and the robot 232 may be used to manipulate a
dispensing device 234 (and, optionally, a torch 236) carried by the
robot 232 so as to at least substantially automatically dispense
bonding material onto an interface between surfaces of the rotating
cutting element 110 and adjacent surfaces of the body 102 that
define the cutting element pocket 112.
[0058] It is understood that embodiments of systems of the present
invention may not include each of a robotic tool body handling
system 210, a robotic cutter handling system 220, and a robotic
cutter bonding system 230, as does the cutting element attachment
system 200 shown in FIG. 2. For example, additional embodiments of
systems of the present invention may include only a robotic tool
body handling system 210 and a robotic cutter handling system 220,
and bonding of the cutting elements 110 to a body 102 of an
earth-boring tool may be conducted manually. Further embodiments of
systems of the present invention may include only a robotic tool
body handling system 210 and a robotic cutter bonding system 230,
and cutting elements 110 may be placed within cutting element
pockets 112 manually prior to bonding the cutting elements 110 to a
body 102 of an earth-boring tool using the robotic cutter bonding
system 230. Yet further embodiments of systems of the present
invention may include only a robotic cutter handling system 220 and
a robotic cutter bonding system 230, without employing a robotic
tool body handling system 210 to manipulate a body 102 of an
earth-boring tool as cutting elements 110 are positioned thereon
using the robotic cutter handling system 220 and bonded to the body
102 using the robotic cutter bonding system 230. In yet further
embodiments of systems of the present invention, a robotic tool
body handling systems 210 may be used to manipulate a body 102 of
an earth-boring tool relative to one or more cutting element
fixtures located in a fixed position in three-dimensional space to
position one or more cutting elements held therein into cutting
element pockets of the body 102.
[0059] FIG. 3A is a perspective view of one particular embodiment
of a cutting element attachment system 200 of the present invention
that may be used to manipulate cutting elements and bodies of
earth-boring tools, and FIG. 3B is a side view of the system shown
in FIG. 3A. The cutting element attachment system 200 shown in
FIGS. 3A and 3B includes a robotic tool body handling system 210, a
robotic cutter handling system 220, a robotic cutter bonding system
230, and a main control system 250 (FIG. 3A), which may be used to
control and/or electrically communicate with one or more of the
controllable subsystems and devices of the cutting element
attachment system 200. The robotic tool body handling system 210
includes a workpiece positioner 212 for holding a body 102 of an
earth-boring tool. The robot 232 of the robotic cutter bonding
system 230 and the robot 222 of the robotic cutter handling system
220 each comprise a six-axis articulated robotic arm. In additional
embodiments, the workpiece positioner 212 also may comprise a
multi-axis robotic manipulator, such as a six-axis articulated
robotic arm.
[0060] FIGS. 3A and 3B illustrate the positioner 212 holding the
body 102 in a particular position and orientation in
three-dimensional space while the robot 222, the cutter holding
device 224, and the power-driven 226 of the robotic cutter handling
system 220 are used to position a cutting element 110 in a cutting
element pocket 112 located on a radially inward cone region on a
face 103 (FIG. 1) of body 102, and the robot 232, the device for
dispensing bonding material 234, and the torch 236 of the robotic
cutter bonding system 230 are used to bond the cutting element 110
to the body 102. The positioner 221 may be used to manipulate the
body 102 into desirable positions and orientations as a cutting
element 110 is positioned within each of a plurality of cutting
element pockets 112 and the cutting elements 110 are attached to
the body 102. FIGS. 4A and 4B are substantially similar to FIGS. 3A
and 3B, respectively, but illustrate the positioner 212 holding the
body 102 in a different position and orientation in
three-dimensional space while the robotic cutter handling system
220 is used to position a cutting element 110 in a cutting element
pocket 112 located on a radially outward shoulder region on a face
103 (FIG. 1) of the body 102, and the robotic cutter bonding system
230 is used to bond the cutting element 110 to the body 102. It may
be desirable to orient each cutting element 110 and the body 102
such that the longitudinal axis of each respective cutting element
110 is disposed transverse (at least generally perpendicular) to
the gravitational field as that cutting element 110 is bonded to
the body 102, as discussed in further detail below.
[0061] FIG. 5 illustrates an embodiment of a cutter holding device
224 of the present invention that may be used in the cutting
element attachment system 200 (FIGS. 3A, 3B, 4A and 4B). The cutter
holding device 224 shown in FIG. 5 includes a magnetic device 260
disposed at an end of a body 262 of the cutter holding device 224.
The magnetic device 260 may comprise at least one physical magnet
261 that provides a magnetic field for holding a cutting element
110 comprising a magnetic material adjacent the magnetic device 260
when the cutting element 110 is brought in proximity to the
physical magnet 261. The magnetic device 260 may be shaped to
provide a groove, recess, or pocket therein, in which a cutting
element 110 may be contained as the cutting element 110 is being
held adjacent the magnetic device 260 by the magnetic field of the
physical magnet 261. For example, the magnetic device 260 may
include a container device 263 (as shown in FIG. 5) that is
configured to contain a cutting element 110 at least partially
therein when a cutting element 110 is being held by the magnet 261
of the magnetic device 260.
[0062] In additional embodiments, the magnetic device 260 may
comprise one or more electrical magnetic devices configured to
generate a magnetic field in place of, or in addition to, the at
least one physical magnet 261 to provide a magnetic field for
holding a cutting element 110 in position against the magnetic
device 260. In additional embodiments, mechanical tweezers or
pinchers may be used in place of, or in addition to, the magnetic
device 260 for holding and carrying a cutting element 110.
[0063] The cutter holding device 224 shown in FIG. 5 also includes
a movable manipulator arm 264. The manipulator arm 264 may be used
to assist in holding a cutting element 110 in place within adjacent
the magnetic device 260 and/or to facilitate the removal of a
cutting element 110 from the magnetic device 260 after the cutter
holding device 224 has been used (in conjunction with the robot 222
(FIGS. 3A, 3B, 4A and 4B)) to place the cutting element 110 into
position on or adjacent a body 102 of an earth-boring tool. As
shown in FIG. 5, the manipulator arm 264 may comprise an elongated
rod member 270 extending from an arm body 271. One end of the rod
member 270 is attached to the arm body 271, and an opposite, free
end 272 of the rod member 270 is positioned proximate the magnetic
device 260.
[0064] The manipulator arm 264 may be movable relative to the
magnetic device 260. For example, the cutter holding device 224 may
include a first air cylinder 266 for selectively moving the free
end 272 of the elongated rod 270 back and forth in a sideways
motion (from the perspective of FIG. 5) toward and away from the
magnetic device 260 in the general direction indicated by the
arrows 281 in FIG. 5. The cutter holding device 224 may include a
second air cylinder 268 for selectively moving the free end 272 of
the elongated rod member 270up and down in a vertical motion (from
the perspective of FIG. 5) relative to the magnetic device 260 in
the general direction indicated by the arrows 279 in FIG. 5. In
additional embodiments, hydraulic cylinders, solenoids, or servo
motors may be used in place of the first and second air cylinders
266, 268 for selectively moving the manipulator arm 264 relative to
the body 262 of the cutter holding device 224.
[0065] A cylinder body of the first air cylinder 266 may be
pivotally attached to a mounting bracket 274 that is fixedly
attached to the body 262 of the cutter holding device 224. A
plunger 276 of the first air cylinder 266 may be pivotally attached
to a cylinder body of the second air cylinder 268. The cylinder
body of the second air cylinder 268 also may be pivotally attached
to a mounting bracket 275, which is fixedly attached to the body
262 of the cutter holding device 224. A plunger 277 of the second
air cylinder 268 is attached to the arm body 271 of the manipulator
arm 264. The arm body 271 of the manipulator aim 264 also may be
movably attached to the body 262 of the cutter holding device 224
using, for example, a support arm 278 to provide additional support
and stability to the manipulator arm 264 while allowing the
manipulator arm 264 to move relative to the body 262 in response to
actuation of the first and second air cylinders 266, 268.
[0066] As the plunger 276 is caused to move out from the cylinder
body of the first air cylinder 266, the movement of the plunger 276
will cause the second air cylinder 268 and the manipulator arm 264
attached thereto to move in the leftward direction (from the
perspective of FIG. 5), thereby causing the free end 272 of the rod
member 270 to move away from the magnetic device 260. Conversely,
as the plunger 276 is caused to move into the cylinder body of the
first air cylinder 266, the movement of the plunger 276 will cause
the second air cylinder 268 and the manipulator arm 264 attached
thereto to move in the rightward direction (from the perspective of
FIG. 5), thereby causing the free end 272 of the rod member 270 to
move toward the magnetic device 260. As the plunger 277 is caused
to move out from the cylinder body of the second air cylinder 268,
the movement of the plunger 277 will cause the manipulator arm 264
attached thereto to move in the downward direction (from the
perspective of FIG. 5), thereby causing the free end 272 of the rod
member 270 to also move in a downward direction away from the
magnetic device 260. Conversely, as the plunger 277 is caused to
move into the cylinder body of the second air cylinder 268, the
movement of the plunger 277 will cause the manipulator arm 264
attached thereto to move in the upward direction (from the
perspective of FIG. 5), thereby causing the free end 272 of the rod
member 270 to move upward and toward the magnetic device 260.
[0067] The first and second air cylinders 266, 268 may be
selectively actuated and controlled by the controller 221 of the
cutter handling system 220 and/or the main control system 250 (FIG.
2).
[0068] After a cutting element 110 held by the magnetic device 260
has been positioned on or adjacent a body 102 of an earth-boring
tool (e.g., in a cutting element pocket 112 (FIG. 1)), the first
and second air cylinders 266, 268 may be selectively actuated to
cause the free end 272 of the elongated rod member 270 to abut
against a surface of the cutting element 110. As the robot 222
(FIGS. 3A, 3B, 4A and 4B) causes the cutter holding device 224
(and, hence, the magnetic device 260) to move away from the cutting
element 110, the first and second air cylinders 266, 268 may be
selectively actuated to cause the elongated rod 270 to hold the
cutting element 110 in position relative to the body 102 until the
magnetic device 260 is far enough away from the cutting element 110
that the magnetic fields of the magnetic device 260 will not cause
the cutting element 110 to move out of position relative to the
body 102. In other words, the elongated rod member 270 may be used
to hold the cutting element 110 in place as the magnetic device 260
is pulled away from the cutting element 110.
[0069] FIG. 6 is an enlarged partial view illustrating the cutter
holding device 224, shown in FIG. 5, being used to position a
cutting element 110 in a cutting element pocket 112 of the body 102
of an earth-boring rotary drill bit 110. In particular, FIG. 6
illustrates the free end 272 of the elongated rod member 270 of
cutter holding device 224 holding a cutting element 110 in position
within a cutting element pocket 112 as the magnetic device 260
(FIG. 5) and other components of the cutter holding device 224 are
drawn away from the cutting element 110 by the robot 222 (FIGS. 3A,
3B, 4A, 4B, and 5).
[0070] FIG. 7 illustrates an embodiment of a power-driven device
226 of the present invention. As previously discussed, the
power-driven device 226 may be carried by an end of the robot 222
and may be located thereon proximate the cutter handling device
224.
[0071] The power-driven device 226 shown in FIG. 7 includes a wheel
280 mounted on an axle 282. An electrical motor 284 is used to
selectively drive rotation of the axle 282 and the wheel 280. A
generally cylindrical lateral side surface 286 of the wheel 280 may
be shaped and otherwise configured to abut against a surface of a
cutting element 110 (such as, for example, a generally cylindrical
lateral side surface 115 of a cutting element 110). In this
configuration, the robot 222 may be used to cause the lateral side
surface 286 of the wheel 280 to abut against a generally
cylindrical lateral side surface 115 of a cutting element 110, and
the electrical motor 284 may be used to drive rotation of the wheel
280 and, hence, the cutting element 110 abutting against the wheel
280.
[0072] As shown in FIG. 7, the wheel 280 may comprise a tapered
surface 288, a ridge, or another feature on the side thereof to
provide a surface against which a peripheral edge of a cutting face
114 of a cutting element 110 may abut when the wheel 280 is being
used to drive rotation of the cutting element 110. In this manner,
the tapered surface 288 may be used in an effort to prevent the
cutting element 110 from sliding or "walking" out of a cutting
element pocket 112 (FIG. 1) as the wheel 280 drives rotation of the
cutting element 110 within the cutting element pocket 112.
[0073] The power-driven device 226 shown in FIG. 7 also may include
a movable arm 300. In some embodiments, the movable arm 300 may be
substantially similar to the manipulator aim 264 of FIG. 5, and may
be selectively actuable in a manner substantially similar to the
manipulator arm 264. The movable arm 300 may include a contact pin
302 or another sensor device on an end thereof, which may be used
for determining a rotational position of a cutting element 110
within a cutting element pocket 112. For example, a line recess 304
may be inscribed or otherwise provided on a lateral side surface
115 of a cutting element 110, as shown in FIG. 7. As the wheel 280
drives rotation of the cutting element 110 within the cutting
element pocket 112, the contact pin 302 may be caused to abut
against the lateral side surface 115 of the cutting element 110. A
sensor may be used to sense when the contact pin 302 is aligned
with and disposed partially within the line recess 304 on the
lateral side surface 115 of a cutting element 110. In some
embodiments, the line recess 304 may be selectively placed on the
lateral side surface 115 of the cutting element 110 such that the
cutting element 110 is in a desired rotational orientation relative
to the body 102 when the line recess 304 is aligned with the
contact pin 302. As a result, the contact pin 302 may be used to
determine a rotational orientation of the cutting element 110
within a cutting element pocket 112 and/or to assist in orienting
the cutting element 110 in a desirable rotational orientation
within a cutting element pocket 112.
[0074] FIG. 8 is an enlarged partial view illustrating the
power-driven device 226, shown in FIG. 7, being used to rotate a
cutting element 110 in a cutting element pocket 112 of the body 102
of an earth-boring rotary drill bit 100 (FIG. 1). In particular,
FIG. 8 illustrates the lateral side surface 286 of the wheel 280
abutting against a lateral side surface 115 of a cutting element
110 as the wheel 280 is being used to drive rotation of the cutting
element 110.
[0075] FIG. 9 is an enlarged partial view illustrating the cutter
holding device 224, shown in FIG. 5, being used to position a
cutting element 110 in a cutting element pocket 112 of the body 102
of an earth-boring rotary drill bit 100 (FIG. 1). Also shown in
FIG. 9 are a dispensing device 234 for dispensing bonding material
and a torch 236 of a robotic cutter bonding systems 230. The
dispensing device 234 shown in FIG. 9 includes a wire feeder device
positioned and oriented to dispense wire bonding material onto an
interface between a cutting element 110 and a surface of the body
102 of an earth-boring tool that defines a cutting element pocket
112 in which the cutting element 110 is disposed. The torch 236
shown in FIG. 9 includes an acetylene torch oriented and positioned
to heat the cutting element 110, the region of the body 102
comprising the cutting element pocket 112, and the wire bonding
material to be dispensed from the dispensing device 234.
[0076] FIGS. 10A and 10B are a flowchart illustrating a method that
may be used to create a computer program, or an actionable system
routine including a plurality of individual programs, for
controlling the cutting element attachment system 200 in accordance
with embodiments of methods of the present invention. As shown in
FIG. 10A, in act 400, a Bit Description File may be input into the
control system 250. Similarly, in act 402, a three-dimensional (3D)
Bit Model File (which may comprise a computer automated drawing
(CAD) file) also may be input into the main control system 250.
[0077] In act 404, an algorithm or script may be executed by the
main control system 250 to extract information from one or both of
the Bit Description File and the 3D Bit Model File relating to the
locations, orientations, and sizes of cutting elements 110 and/or
cutting element pockets 112. The information extracted in act 404
may be written to a data file in act 406, which may be stored in
the main control system 250. In act 408, an algorithm or script may
be executed by the main control system 250 in which the data file
generated in act 406 is used to generate motion programs that
determine the paths to be followed by the positioner 212 of the
robotic tool body handling system 210, the robot 222 of the robotic
cutter handling system 220, and the robot 232 of the robotic cutter
bonding system 230. As an example, a general tool path or motion
program template may be used for a certain type or class of drill
bit 100, and the data file generated in act 406 may be used to
modify the motion program template to provide the paths to be
followed by the positioner 212, the robot 222, and the robot 232
for a particular drill bit 100 or other tool to be processed using
the cutting element attachment system 200.
[0078] With continued reference to FIG. 10A, in act 410, an
algorithm or script may be executed by the main control system 250
to extract information from one or both of the Bit Description File
and the 3D Bit Model File that may be used to determine processing
parameters such as thermal processing parameters for the robotic
cutter bonding system 230. For example, in act 410, an algorithm or
script may be executed by the main control system 250 to extract
information relating to the size, type, and material composition of
cutting elements 110 and/or to the size, type, and material
composition of the body 102 of the drill bit 100. In act 412, the
information extracted in act 410 may be used to determine
processing parameters, and the processing parameters may be written
to a data file, which may be stored in the main control system 250.
Such processing parameters may include, for example, the "on times"
for the torch 236, bonding material feed rates and times for the
dispensing device 234 for dispensing bonding material, orientation
of the bit body 102, and a target temperature at which it is
desirable for bonding to occur. In act 414, an algorithm or script
may be executed by the main control system 250 in which the data
file generated in act 412 is used to generate bonding process
parameter programs that may be used to control the torch 236 and
the dispensing device 234 for dispensing bonding material. Similar
processes may also be used to generate programs for controlling
other components of the cutting element attachment system 200 such
as, for example, the cutter holding device 224 and the power-driven
device 226 of the robotic cutter handling system 220.
[0079] In act 420, the main control system 250 may be used to
create an actionable system routine that includes the various
computer programs that will be used to synchronously control the
various active components and systems of the cutting element
attachment system 200, and to generate one or more data files
defining the actionable system routine, and such data files may be
stored in the main control system 250.
[0080] In some embodiments, acts 400 through 420 may be carried out
using one or more computer systems separate from the main control
system 250 or any other controller of the cutting element
attachment system 200 shown in FIG. 2. In other embodiments, one or
more of acts 400 through 420 may be carried out using the main
control system 250 or another controller of the cutting element
attachment system 200 shown in FIG. 2.
[0081] Referring to FIG. 10B, in act 422, the motion programs of
the actionable system routine may be used to simulate movement of
the various components of the cutting element attachment system 200
relative to the bit body 102 to verify that no physical
interference problems will occur during a cutting element
attachment process, and to ensure that the cutting element
attachment process may be successfully carried out using the motion
programs. Any potential problems may be identified, and the motion
programs may be modified to resolve such problems prior to actual
execution of the actionable system routine by the cutting element
attachment system 200.
[0082] The actual positions and orientations of the cutting
elements 110 and the cutting element pockets 112 of a drill bit 100
or tool may deviate somewhat from the intended positions and
orientations of the cutting elements 110 and the cutting element
pockets 112 of a drill bit 100 or tool due to inherent variations
in the manufacturing processes used to form such drill bits 100 and
tools. Therefore, in some embodiments of the present invention, one
or more sensors 240 or sensor systems, as previously described
herein, may be used to identify any differences between the actual
positions and orientations of the cutting elements 110 and the
cutting element pockets 112 of a drill bit 100 or tool and the
intended positions and orientations of the cutting elements 110 and
the cutting element pockets 112.
[0083] With continued reference to FIG. 10B, in act 423, the main
control system 250 may generate one or more text files that include
one or more computer programs for causing the one or more sensors
240 to inspect a bit body 102 carried by the positioner 212 to
identify differences between the intended locations and
orientations of the cutting element pockets 112.
[0084] In some embodiments, acts 422 and 423 may be carried out
using one or more computer systems separate from the main control
system 250 or any other controller of the cutting element
attachment system 200 shown in FIG. 2. In other embodiments, one or
more of acts 422 and 423 may be carried out using the main control
system 250 or another controller of the cutting element attachment
system 200 shown in FIG. 2.
[0085] In act 424, the main control system 250 may use these
generated text files to cause the one or more sensors 240 (e.g., a
vision system) to inspect a bit body 102 carried by the positioner
212 to identify differences between the intended locations and
orientations of the cutting element pockets 112, as set forth in
the design of the bit body 102, and the actual locations and
orientations of the cutting element pockets 112 in the
as-manufactured bit body 102. In act 425, the data or information
acquired by the sensors 240 relating to the actual positions and
orientations of the cutting element pockets 112 may be used to
modify the motion programs that determine the paths to be followed
by the positioner 212, the robot 222, and the robot 232 for a
particular drill bit 100 or other tool to be processed using the
cutting element attachment system 200.
[0086] The actual positions and orientations of the cutting element
pockets 112 of a body 102 of a drill bit 100 or other tool also may
change with changes in temperature due to thermal expansion and
contraction. In some embodiments of the present invention, the bit
body 102 may be preheated to a desirable temperature prior to
attaching cutting elements 110 to the bit body 102. Furthermore, as
the temperature of the body 102 is altered using the torch 236 of
the robotic cutter bonding system 230, the positions and
orientations of one or more cutting element pockets 112 may
slightly change due to thermal expansion of the material of the
body 102. As shown in FIG. 10B, in act 426, the main control system
250 may be used to modify the motion programs to compensate for
changes in cutting element position due to thermal expansion. One
or more sensors 240 or sensor systems, as previously described
herein, may be used to determine and/or monitor a temperature of
one or more of a bit body 102 and a cutting element 110. Once the
temperature of one or more of a bit body 102 and a cutting element
110 is determined, changes in the actual positions and orientations
of the cutting elements 110 and the cutting element pockets 112 of
a drill bit 100 or tool due to variations in temperature may be
calculated using known thermal expansion coefficients of the
materials of the cutting elements 110 and the bit body 102. The
calculated changes in the positions of the cutting element pockets
112 thus acquired may be used to determine or adjust the paths to
be followed by the positioner 212 of the robotic tool body handling
system 210, the robot 222 of the robotic cutter handling system
220, and the robot 232 in the motion programs.
[0087] As shown at act 428 in FIG. 10B, once the paths to be
followed by the positioner 212 of the robotic tool body handling
system 210, the robot 222 of the robotic cutter handling system
220, and the robot 232 of the robotic cutter bonding system 230
have been determined, the computer code of the actionable system
routine may be executed in at least one of the main control system
250, the controller 214 of the robotic tool body handling system
210, the controller 221 of the robotic cutter handling system 220,
and the controller 231 of the robotic cutter bonding system 230 to
cause the positioner 212, the robot 222, and the robot 232 to at
least substantially automatically perform their respective
functions to attach one or more cutting elements 110 within the
cutting element pockets 112 of the drill bit 100 or other tool.
[0088] Upon execution of the computer code of the actionable system
routine, the robot 222 of the robotic cutter handling system 220,
the robot robotic 232 of the cutter bonding system 230, and the
positioner 212 of the robotic tool body handling system 210 may be
indexed to a first position for attaching a cutting element 110 to
the body 102 within a cutting element pocket 112. The robot 222 and
cutter holding device 224 may be used to retrieve a cutting element
110 from a pre-loaded tray of cutting elements 110. The robot 232
and the torch 236 carried thereby may be used to heat the region of
the body 102 comprising the cutting element pocket 112. Optionally,
a flux material also may be applied to the cutting element pocket
112 using the robot 232. After the robot 232 and the torch 236 are
used to heat the region of the body 102 comprising the cutting
element pocket 112, the robot 222 and the cutter holding device 224
then may be used to position the cutting element 110 within the
cutting element pocket 112. After positioning the cutting element
110 within the cutting element pocket 112, the power-driven device
226 carried by the robot 222 may be used to drive rotation of the
cutting element 110 within the cutting element pocket 112 as the
robot 232, the dispensing device 234 for dispensing bonding
material, and the torch 236 are used to apply the bonding material
to the interface between the cutting element 110 and the surfaces
of the body 102 defining the cutting element pocket 112. The
power-driven device 236 then may be used to rotate the cutting
element 110 into a desirable rotational position within the cutting
element pocket 112, prior to allowing the bonding material to
solidify, cure, or otherwise fix the cutting element 110 in place
within the cutting element pocket 112.
[0089] As the cutting element 110 is attached to the body 102
within the cutting element pocket 102, it may be desirable to
maintain a temperature of the cutting element 110 below a
temperature at which the cutting element 110 may be damaged. For
example, if the cutting element 110 comprises a polycrystalline
diamond compact (PDC) cutting element, it may be desirable to
maintain the cutting element 110 at a temperature below about
750.degree. C. to avoid damaging the cutting element 110. As a
result, the sensors 240 may be used to monitor the actual
temperature of the cutting element 110, and the heat output by the
torch 236 may be controlled to maintain the temperature of the
cutting element 110 below a predetermined threshold level.
[0090] The computer code of the actionable system routine may cause
the cutting element attachment system 200 to repeat the
above-described process for each of the cutting elements 110 to be
attached to the body 102 of the earth-boring tool.
[0091] Embodiments of the present invention also may be used in the
disassembly and/or repair of previously used drill bits 100 and
other tools. For example, the cutting element attachment system 200
previously described herein could be programmed to at least
substantially automatically remove cutting elements from a used
drill bit 100. The robotic cutter bonding system 230 may be
programmed to use the torch 236 thereof to apply heat to an
interface between a cutting element 110 and an adjacent surface of
a bit body 102 until a bonding material at the interface (e.g., a
metal alloy braze material) melts or decomposes, and the robotic
cutter handling system 220 may be programmed to then remove the
cutting element 110 from the bit body 102. This process could be at
least substantially automatically repeated for each of the cutting
elements 110 of the drill bit 100. Optionally, the cutting element
attachment system 200 could then be used to place new replacement
cutting elements 110 in the cutting element pockets 112 of the
drill bit 100 as part of a repair process. When used for repair,
the cutting element attachment system 200 also may include
automated equipment for machining (e.g., grinding, milling,
drilling, etc.) the cutting element pockets 112 and other regions
of the bit body 102 of a drill bit 100 as necessary or desirable
during the machining process.
[0092] As the methods disclosed herein are at least partially
automated, they may be conducted without a human operator being
located in the immediate vicinity of the body 102 to which cutting
elements 110 are being attached. As a result, the processes may be
carried out in environments that would be harmful or dangerous to
human operators. For example, embodiments of the systems disclosed
herein may be positioned within an enclosed chamber or room, and
the environment in the enclosed chamber or room may be controlled
as embodiments of methods of the present invention are carried out
using embodiments of systems of the present invention, as disclosed
herein. Various aspects of the environment within such an enclosure
may be controlled including, for example, the temperature within
the enclosure, the pressure within the enclosure, and the
composition of the gas or gases within the enclosure. For example,
in some embodiments, the environment within such an enclosed
chamber or room may be an oxygen-free environment, a reducing
environment, or some other environment that would not be a suitable
environment for a human operator, but would be beneficial when
attaching a cutting element 110 to a body 102 of an earth-boring
tool. In additional embodiments of the present invention, the
methods disclosed herein may be carried out under controlled
atmospheres, thereby allowing the use of certain bonding materials
that could not easily be used in previously known processes in
which cutting elements 110 were manually attached to a body of an
earth-boring tool.
[0093] While the embodiments of the present invention are described
herein in relation to earth-boring rotary drill bits having fixed
cutters and to methods for forming such drill bits, embodiments of
the present invention also may be used to form other types of
earth-boring tools such as, for example, reamers, mills, and
so-called "hybrid bits" that include both one or more roller cones
in combination with fixed cutters carried on blades or other
supporting structures. Thus, as employed herein, the term "drill
bit" includes and encompasses all of the foregoing earth-boring
tools, as well as components and subcomponents of such
structures.
[0094] While the present invention has been described herein with
respect to certain embodiments, those of ordinary skill in the art
will recognize and appreciate that it is not so limited. Rather,
many additions, deletions and modifications to the embodiments
described herein may be made without departing from the scope of
the invention as hereinafter claimed. In addition, features from
one embodiment may be combined with features of another embodiment
while still being encompassed within the scope of the invention as
contemplated by the inventor.
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